JPH03206185A - Carpet tile and its manufacture - Google Patents

Abstract

PURPOSE: To inexpensively obtain a carpet tile rich in dimensional stability by laminating a backing layer comprising a specific hot melt composition and a secondary backing layer containing a fiber sheet layer and a glass fiber layer to the bottom of a carpet material having an upper wear surface and an lower under surface. CONSTITUTION: A first backing layer comprising a solid hot-melt composition having >=140 deg.C coating temperature on the lower side bottom of a tufted carpet material 12A composed of a synthetic fiber such as nylon and having an upper wear surface and a lower bottom and then, a secondary backing layer bonded to the above backing layer and composed of a nonwoven, porous and fibrous sheet material 22 (e.g. polypropylene) having tend to melt or deform at >=140 deg.C and forming outside second backing surface of the carpet tile and a porous lightweight glass fiber 20 and penetrating a bitumen composition 18 provided in the lower bottom into the glass fiber sheet 20 and partially penetrating the composition into the fiber sheet 22 is adjacently provided and fixed to provide the objective carpet pile excellent in dimensional stability.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Field of Application 1] The present invention relates to tiles and their manufacturing method.

PRIOR ART Carpet tiles having a fibrous or abrasive surface and a solid backing layer of hot-melt composites, such as solid or atactic polypropylene, are well known and are capable of resisting forces of this type. 1 Pet Thai Inole and this kind of carpet 1 - The method for producing Thai Inole is
U.S. Patent No. 4,582, issued April 15, 986.
. These are waiting for us! '{ supports a substrate such as ant-free layer 1~ or a second backing layer, applies a layer of liquid bitumen hot 1/melt composite material to the substrate, and places it on the carrier A7. The back side of the carpet material, which may be suitably precoated with a liquid hot melt composition, is laminated and the carpet laminate is cooled! The present invention also describes a method of manufacturing a single bed tile with a backing layer of a hot melt bituminous composition by cutting a Carpet 1 laminate into Carpet 1 tiles.

The laminated sheet material can be used as a carpet without a separate removable endless gear belt, and the roughly laminated material can be used as a second backing for carpet tiles produced in this way. can be a direct part of The back j7 sheet 1 can be a laminate of glass and polythene film, ie, a laminate of polyethylene film, and the surface of this film can be applied directly to the carrier belt. Suitable laminate backing sheets disclosed include glass and polyurethane finolems or glass bottles.
In this method, which involves a laminate of ethylene-glass or polyester cloth or paper and polyethylene film, the high-performance laminate backing sheet must be substantially resistant to penetration of the hot-melt liquid composition. is essential. This backing sheet 1~ is useful in imparting non-slip and dimensional stability properties to the resulting carpet tile.

In one method of manufacturing carpet tiles, a layer of hot-melt silk, such as a modified bituminous composition, is coated onto an elongated fibrous carrier sheet, which carrier sheet serves as a second layer for carpet tiles. This will be the backing sheet. Generally, polypropylene or a blend of polypropylene and polyester nonwoven ivIt is used as the second backing carrier sheet. However, polypropylene sheets have low melting and deformation temperatures, such as temperatures 20 to 30 degrees Celsius (eg, temperatures of about 130 degrees Celsius) below the application temperature of hot melt composites. The hot melt composition is
A predetermined thickness [e.g. 20-60 mils (e.g. 0.05
~0.15cm)] 4 liquids viscous hot 1~menole I
~Temperature sufficient to provide IH material, e.g. generally 1
It is applied to the carrier sheet material or carrier belt at a temperature of 40 DEG to 170 DEG C., for example 150 DEG to 160 DEG C., resulting in the deformation of the polypropylene fibrous sheet.

Therefore, the polypropylene nonwoven sheet + material A is the second
The material is not satisfactory as a backing carrier sheet.

As the second backing sheet, a synthetic fiber-backed carrier sheet is used, such as an expensive and high temperature resistant polyester sheet, such as a spun-bonded polyester handwoven material known as Vizim 100 from Ron Poulenc. has been done. Backing materials of this type are used because of their high heat resistance and high stability, and their use tends to prevent strain build-up in the resulting carpet tiles and thus improve the dimensional properties of the product.

However, this type of high temperature resistant synthetic fiber (eg polyester fiber #1) is extremely expensive.

Therefore, the key τ of the conventional technology at a low price! It would be desirable to provide a carpet tile and method of making the same that has improved dimensional stability without the difficulties and disadvantages associated with the use of a second A7 sheet backing layer.

SUMMARY OF THE INVENTION The present invention relates to carpet tiles and methods of manufacturing carpet tiles. More particularly, the present invention relates to improved dimensional stability carpet tiles having a second backing sheet and a method of manufacturing carpet tiles of good dimensional stability at low cost.

The carpet tile of the present invention has a wear surface and a bottom surface made of carpet material, and has a roughly solid hot melt 1.
a second backing comprising a backing layer of tissue and an adjacent layer of porous glass fiber sheet material, such as non-woven glass fiber and porous fiber sheet material; 2, the outer surface of the backing layer, and the hot melt composition penetrates and partially penetrates the fiberglass material sufficiently to saturate and bind the fiberglass material. do. Typically, carpets 1
~The tile is made of G&V carpet material, where the second backing composition is bitumen or bitumen modified hot melt crude. The second backing layer consists of a porous lightweight glass i-fibrous sheet material and a lightweight porous non-woven fibrous sheet material (
polypropylene> sheet material, the fibrous sheet material forming the outer surface of the second backing layer and the bituminous composition only partially covering the fibrous sea material (e.g. 50%> penetration, and furthermore, the outer surface does not substantially contain the hot melt backing layer.
Penetration through the material to the outer surface is undesirable.

The method for manufacturing carpet tiles comprises placing a glass fiber sheet material on top of a porous fibrous sheet material, and in one embodiment, an adjacent layer of the glass fiber sheet material and the fibrous sheet material is hot. Forming a carrier sheet for the melt composition. The method includes applying a layer of a thermal liquid hot melt composition to an upper surface of a glass fiber sheet material. The viscous hot melt composition is then pressed into the porous glass fiber material, for example by using a transfer roll technique, and the hot melt composition forms a backing layer with glass fibers and the fiberglass sheet material. The fibrous nonwoven sheet material is partially and slightly press-fitted to provide a good bond between. As in conventional carpet tile manufacturing, additional layers of hot melt laminate may be applied with or without fiberglass scrim or other sealing materials placed within the backing layer. The carpet material is then laminated to the hot melt composition at a lamination station, then controlled cooling at a cooling station and cut into carpet tiles at a cutting station.

The carpet tile of the present invention and its manufacturing method are
This provides significant advantages both in terms of dimensional stability) and the cost of the carpet tile, as well as the method of manufacturing the carpet tile. As the second back FJ layer, instead of much more expensive and high temperature flame resistant fibers such as aramid U & string, we use much lower cost fibrous sheet materials (e.g. polyester) and low temperature fibrous sheets. materials (e.g. polypropylene). Lightweight non-woven flexible fiber materials, such as non-woven polypropylene sheet materials, can be used in combination with fiberglass tissue sheet materials to reduce handling and manufacturing When flexed, the glass fiber sheet material serves to shield the low cost fibrous sheet material from the high temperatures of the viscous hot melt 1-composition layer during its application, as well as to prevent the glass fibers from breaking. The combination of sheet material and non-woven fibrous sheet material (e.g. polypropylene) can be used to produce carpets 1-
It helps impart high mechanical stability to the tile, providing improved dimensional stability and reducing strain build-up commonly found in the manufacture of carpet tiles. This carpet tile and its manufacturing method provides significant cost savings and a more stable second backing of the tiles.
and second backing J], and great flexibility in the selection of the second backing material.

The Hot Mel 1~ composition is applied to the second backing carrier sheet by a transfer roll coating system to adjust the thickness of the backing layer. The use of a heated doctor plate as an applicator is undesirable when the carrier sheet is more than 2 meters wide because it is difficult to maintain a straight doctor blade without losing accuracy in the backing thickness. When a doctor blade is used in this method, the carrier sheet is driven by rollers at the lamination station. The use of transfer roll application tends to press the hot melt composition into the lightweight sheet of the second backing sheet, thus increasing the viscosity of the true melt composition or lowering the temperature of the hot melt composition. must be used to prevent complete penetration.

Generally speaking, transfer hole application increases the tension in the carrier sheet and also results in a slight elongation of the carrier sheet.

However, the use of glass fiber tissue sheets creates tension. This is because, unlike the fibrous second backing, it is commercially non-stretchable. The adjacent layer of glass fiber tissue sheet material serves to shield the lower fibrous sheet material from the high temperatures of the melt assembly and to prevent shrinkage of the fibrous sheet material. For example, if a polypropylene nonwoven sheet material is used, the polypropylene U&fibers will be soft but held in a substantially uncontracted position by an adjacent contact stabilizing layer of glass fiber tissue material.

The carpet material used in carpet tiles may consist of a carpet material having an abrasion surface (typically a fibrous abrasion surface) and a bottom surface that improves the tuff lock of the SUt and/or It may or may not be precoated to promote better adhesion and bonding to the backing layer.

Typically, the carpet material is comprised of natural or synthetic fibers, such as nylon, or mixtures thereof, with a fibrous wear surface treated with Tough 1 or inserted into a first backing sheet;・Material 1/) IL:C
Forms a dark blue backbone as FIn.

A hot melt silk suitable for use as a backing layer may be composed of any hot melt material, such as bitumen or modified bitumen, but typically hot melt silk is suitable for use as a backing layer. - The silk is liquid or viscous at temperatures above 140°C, for example from about 145 to 180°C, and has a molecular weight of about 60,000 to Hl(.), 000
CpS or 200, OOO~100,000C
It has a viscosity up to PS. Hot to melt application temperatures generally tend to deform low cost polyolefin fibers, such as polypropylene fibers, and approximately 13
It has a tendency to deform at temperatures between 0 and 140°C. Do not use protective glass fiber tissue sheet materials! The IP version of Vio Sheet Materials is unsuitable for the purpose of the present invention. The hot-melt compositions can be applied as one layer or generally as two separate layers, with sheet materials to improve dimensional stability optionally added between or within the layers, such as with glass let scrim materials. Can be used.

Generally and preferably, the hot melt composition comprises a bitumen-modified silk composition and can be applied as a liquid at a temperature in the range of about 145-160°C. The composition comprises a viewmen, a particulate filler (e.g., limestone or other filler particles or mixtures thereof), and a modifier (e.g., styrene in an amount sufficient to impart improved and enhanced adhesion properties to the hot melt composition). (a thermoplastic block copolymer of butadiene-styrene). Although bitumen may also be used, modified bituminous hot melt compositions containing small amounts of polymeric modifiers can be used to improve flexibility and adhesion. It is desirable to improve the properties and reduce the viscosity of the hot melt composition, for example in an amount of 3 to 25% by weight, such as 5 to 20%.Suitable modifying polymers include, but are not limited to, polybutadiene, Ethylene vinyl acetate, EPD
M and styrene-butadiene-styrene copolymers, especially branched thermoplastic SBS block copolymers.

Modifying polymers can be used alone or in combination, preferably SBS copolymers are used in conjunction with modifying oils to reduce viscosity and improve Bots 1 and Mel 4 properties.
A') It is possible to promote the separation of polymers for export into l'l. In general, SBS block copolymers are used with modifying hydrocarbon oils such as Nanoten to promote fractionation into bitumen (e.g. 198
U.S. Patent No. 4,201,812, issued May 6, 2013.
No. 1, cited here for reference. The modifying oil has a weight loss of 30 to 80%, for example 55 to 70%, relative to the modifying polymer.
% by weight. Granular filler 44 is used to reduce cost and lactic properties, and the amount is generally 30-80% by weight of the hot melt 1 to composition;
For example, it is in the range of 50 to 70% by weight.

Glass fiber sheets suitable for use in the second back '4]
The material is a porous woven fiberglass tissue sheet material, preferably a lightweight porous non-woven resin bonded fiberglass tissue material. This tissue material has sufficient porosity to allow penetration of the viscous hot melt composition at hot melt application temperatures, and sufficient iM fibrous body to protect the underlying composite fibrous sheet material. Should have. The glass fiber tissue material must be heat resistant to TIF, inexpensive, and non-shrinkable to simulate conductive strain build-up. Glasses with large continuous pores spaced apart as standard (11) are not suitable for use in the second backing sheet.
Il2 has a weight of e.g. 30-40 g/m2,
resin bonded, e.g. having 10-25% by weight of resin, with a fiber diameter of about 8-15 mm, e.g. Thickness of mil (0.06~Olcm) and about 2.0~8.0 (mmW.G.(c)),
For example, it has a porosity of 3.5 to 4.5. Porosity is measured as the pressure drop for a known air flow rate of 2000j/m 2 /sec across the tissue.

The fibrous sheet material used in combination with the glass fiber sheet material as the second backing may be a porous synthetic fibrous sheet material or a hot melt composite, e.g. Other fabrics that have a tendency to melt or deform at temperatures of about 140° C. or higher may be used. Unrelated or cheap 4I polyester fiber sheet I ~ monthly fee is about 15-65 mils (0.04-0.17 cm),
For example, 20 to 50 mils (0.05 to 0.13 cm)
) thickness and about 30-100g/m2, e.g. 40-6
It can be constructed of a lightweight porous non-woven type material with a weight of 0 g/m2.

Non-woven (eg, polypropylene) fibrous sheets can be formed into cohesive sheet materials by resin bonding, spin bonding, embossing, gluing, or other methods. Polypropylene fibers can be used alone or blended with other composites or fibers such as polyester, or polypropylene can be used over or in conjunction with the core RM material. Furthermore, a lightweight polyester sheet material can also be used as the second backing sheet material. Generally, 50% as well as non-woven polyester
Lightly crushed fibrous sheet material less than ~70g/H2
It cannot be used as a backing. This is because the true melt composition penetrates to the outer back surface. However, glass l! The use of fibrous materials can provide sufficient penetration to provide effective wilting without Ka-transmission problems, and is effective in preventing perfusion.

In one preferred embodiment, the second backing layer acts as a carrier for applying the Bot 1 melt composition as a backing layer. However, it is recognized that a separate carrier belt with a removable type of surface can be used, or the hot melt composition can be applied directly to the surface of the cappet and the second backing can be applied directly to the hot melt composition. It will be done.

The second backing sheet is comprised of adjacent contact layers of glass fiber tissue and lAIi fibrous sheet material. The glass fiber tissue material and the fibrous sheet material can also be applied separately during manufacturing. The glass fibrous material shields the polypropylene fibers from the high temperatures of the viscous fibers, while the relatively thick polypropylene sheet material acts as a flexible carrier and shields the relatively thin glass fibers. Prevent tissue materials from being destroyed during manufacturing and handling processes. This combination provides a carpet with good dimensional stability. For the second lining, when applying the first hot melt composition to the melt composition backing 4, the hot melt composition is easily pressed by the transfer port-lubricator and penetrates into the glass fiber silk fabric, and the non-woven fiber It is sufficiently porous to penetrate the sheet and ensure good mechanical bonding upon cooling of the hot 1-melt composition. Typically, the hot melt mixture is visible from the back side of the rice grain, but does not extend to the outer surface. Generally, the total thickness of the second backing of glass fibers and nonwoven fibrous sheets ranges from about 80 to 120 (1/m2) or 50 to 10 mils (0.13 to 0.25 cm). be.

[Examples] The present invention will be described below for illustrative purposes with reference to illustrative examples, but it will be apparent to those skilled in the art that various modifications, changes, additions, and improvements can be made without departing from the spirit and scope of the present invention. will be understood.

In FIG. 1, a fibrous tufted sheet 12 of, for example, nylon is tufted through a first backing sheet 14 and the back side 16 is tufted.
The upper tuft shows a carpet tile 10 constructed of carpet material 12A8.

The forceps 110 and 12A are secured to a backing layer 18 of modified Vidikomen silk composition which contains a glass miscellaneous sheet material 26 between the separately heated backing layers. Modified bitumen kumikaimono consists of the following: Material Part by weight Bitumen 27,68BS-
Block copolymer 4.9 modified naphthenic oil
2.5 Limestone filler
65.0100. ○ The second lining is made of lightweight glass fiber tissue Sea 1/Material 20 (
33 (J/m2, resin bonded, 30 mil (0.0
76 cm) and porosity 3,8〉, spun-bonded polypropylene bonded by embossing, i.e. a non-woven sheet material 22 (50 CI/m 2 , 30 mil (o.o.
yecm)). The layer 18 of the solid hot melt composition permeates and saturates the layer 20 and partially permeates the layer to impregnate li'ji 2 2 , but the layer 22
24 does not contain a hot melt composition.

Figure 12 shows a method 40 for manufacturing carpet tile 10, in which carpet material 12A is placed in a viscous solid-melt cement composition 18, then laminated and the carpet is passed through cooling zone 62 and cutting zone 64. The method 40 uses a roll of Noras strand weave 20 and a roll of non-woven polypropylene 22 fed through a free wheel mouth 44, and the loose fit of sheets 20 and 22 is passed through a Kirelia seam. 1 is formed as a second backing for tiles 1 to 10. 145 to 155°C and 60,000 to 80, OOO to 100,000CP
The first coating layer 18 of the viscous liquid hot melt 1 to composition of S is applied by a transfer roll applicator, and the large mouth roller 5 is applied.
0 and a small roller 48 with a scraper blade 46 to remove the bituminous silk from the clockwise rotating surface of the roller 48 and deposit a controlled thickness of the modified bitumen boll 1-melt composition into a glass fiber structure. Sheet material 20
A viscous hot melt silk composition 18
A glass woven sheet 20c. : It is pressed and further penetrated partially and slightly into the porous polypropylene sheet 20. After that, cold IJ is carried out in the cooling zone 52 where the material yield is controlled.
L, . . . A layer of glass fiber tissue material 26 is placed on the top surface of the first backing layer as shown if desired. An additional backing layer of hot-melt knitted material 18 is applied to the textured material 26 with another transfer roll applicator (using the same or similar technique as in the first applicator), with heating ports 42 and 66 The bottom surface of the carpet material 12A is then applied using a blade 56, placing the carpet material 12A on the viscous upper surface of the second layer and a controlled cooling zone via opposing driven lamination nip rolls 58-60. 6
2 to solidify the hot melt composition 18, and the resulting laminated carpet material is cut to a carpet tile by a cutting strip 64, and the carpet material 10 is
Collect.

The force one bet tile 10 has an improved second cusp 4J with improved dimensional stability and a low list price bonded to a backing layer.
I can work hard.

1~ IhJ-ff carpet tiles

[Brief explanation of drawings]

FIG. 1 shows a carpet according to the present invention. A cross-sectional view, FIG. 2 shows a carburetor according to the present invention. Figure 2 is a schematic diagram of the method. Enlargement of tiles Manufacture of tiles 10...carpet tile 12A...Carpet 1/Material 14...1st back sea 1~ 18... Hot 1 ~ Melt composition Procedural formalities (method) February 19, 1991

Claims (10)

[Claims] (1) A backing consisting of (a) a carpet material having an upper wear surface and a lower bottom surface; and (b) a solid hot melt composition bonded to the lower bottom surface of the carpet material and having an application temperature greater than 140°C. (c) a second backing layer bonded to the backing layer of the hot melt composition, said second backing layer (i) having a tendency to melt or deform at temperatures greater than 140°C. (ii) a layer of non-woven, porous, temperature-sensitive, fibrous sheet material comprising: a layer of non-woven, porous, temperature-sensitive, fibrous sheet material having an outer secondary backing surface of the carpet tile; and (ii) protecting the temperature-sensitive sheet material from the hot melt composition upon application. and an adjacent layer of porous nonwoven glass fiber tissue sheet material having sufficient porosity to force the hot melt composition through the bonded backing layer saturated with the hot melt composition upon application. a carpet tile, wherein the adjacent layer of fibrous sheet material is partially saturated with a hot melt composition and combined with an outer backing surface of a fibrous sheet material substantially free of hot melt composition. . (2) A carpet tile according to claim 1, wherein the fibrous sheet material has a weight of 20 to 100 g/m^2. 3. The carpet tile of claim 1, wherein the fiberglass tissue sheet material comprises a nonwoven resin-bonded glass fiber porous tissue sheet material having a porosity of 2.0 to 8.0. 4. The carpet tile of claim 1, wherein the fibrous sheet material comprises a non-woven polyester sheet material having a weight of 70 g/m^2 or less. (5) In manufacturing carpet tiles from a carpet material having an upper abrasion surface and a lower bottom surface, (a) a porous, non-stretchable fiberglass tissue sheet material is formed into a flexible, porous, nonwoven, temperature sensitive material; forming a carrier sheet for the tissue sheet material by placing it directly adjacent to a layer of fibrous tissue sheet material, said fibrous sheet material having a tendency to melt or deform at temperatures above 140°C; (b) applying a first backing layer of a viscous liquid hot melt composition to the surface of the glass fiber tissue sheet material, the hot melt composition having an application temperature greater than 140°C; and (c) being driven. A rolling roll applicator forces the viscous liquid hot melt composition of the backing layer to penetrate the porous glass fiber tissue sheet material and partially penetrate the fibrous sheet material, but not the outer backing of the fibrous sheet material. (d) contacting the hot melt composition of the first backing layer with the bottom surface of the carpet material; and (e) cooling the hot melt composition while in contact with the bottom surface of the carpet material to form a base layer of the carpet material. A method of making a carpet tile comprising: forming a solid hot melt composition backing layer bonded to the bottom surface; (f) optionally cutting the cooled backing layer carpet material down to the carpet tile. (6) Glass fiber tissue sheet material is 25 to 80 g/m
6. The method of claim 5, comprising a resin bonded tissue sheet material having a weight of ^2. 7. The method of claim 5, wherein the fibrous sheet material comprises a lightweight polyester or polypropylene sheet material having a weight of less than 70 g/m^2. 8. The method of claim 5, wherein the fiberglass tissue sheet material has a porosity of 2.0 to 8.0 and a thickness of 20 to 80 mils (0.05 to 0.20 cm). (9) Viscous liquid hot melt composition is 60,000 to 1
6. The method of claim 5, wherein the fiberglass tissue sheet material has a porosity of 2.0 to 8.0 while having a viscosity of 0.00000 CPS. (10) A carpet tile manufactured by the method according to claim 5.